Surge-resistant and abrasion-resistant flexible insulating enamel

Abstract

A surge-resistant and abrasion resistant flexible insulating enamel has resin in an amount of 12 wt % to 76 wt % per 100 wt % by weight of the enamel, an organic solvent in an amount of 20 wt % to 80 wt % per 100 wt % by weight of the enamel, polyethylene oxide (PEO) intercalated clay in an amount of 0.005 wt % to 16 wt % per 100 wt % by weight of the enamel, and organic dispersible silica nano-particles in an amount of 0.995 wt % to 16 wt % per 100 wt % by weight of the enamel. The clay and silica nano-particles have high dielectric constant to absorb, disperse evenly and evacuate surge, which prevents an insulating layer made by the insulating enamel from being damaged from the surge. PEO provides the insulating layer has good flexibility, adhesion and abrasion resistance.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of Invention[0002]The present invention relates to an insulating enamel and more particularly to a surge-resistant insulating enamel with excellent abrasion resistance and flexibility for application to a conductor to form an enameled wire.[0003]2. Description of the Related Art[0004]Recent environmental events have encouraged many countries to save energy and reduce CO2 output. Therefore, several protocols and strategies have been established, including, energy-saving inverters. Inverters control the rotation speed of the motor by changing voltage and frequency. Therefore, the motor has improved loading and drive efficiencies. Accordingly, regenerative power can be used for a motor with the inverter due to the inverter saves energy.[0005]Inverters can also be applied to various other systems, including, intelligent power modules (IPMs) using the inverter due to its small size and reduced cost. Furthermore, multiple inverters may be connecte...

AI Technical Summary

Benefits of technology

[0012]The primary objective of the present invention is to provide a surge-resistant insulating enamel with excellent abrasion resistance and flexibility for being applied to a conductor to form an enameled wire.

[0014]The clay and silica nano-particles have high dielectric constant that can absorb, disperse evenly and evacuate surge, which prevents an insulating layer made by the insulating enamel of the present invention from being damaged from the surge. Furthermore, PEO is flexible, facilitates the clay to distribute uniformly into the resin and can be bond with the resin, so the insulating layer has good flexibility, adhesion and abrasion resistance.

Problems solved by technology

The surge can be observed in an oscilloscope, which presents an abnormally high and abrupt pulse among a serious of stable pulses that also means voltage level or current changes suddenly during a serious of stable signals.

Although the power station has protection mechanism, some surges may be still transmitted because the protection mechanism has a limit.

Furthermore, the protection mechanism may generate a surge, such as, a switch in a house being turned on or off.

Sometimes, the surge may destroy electronic devices such as computers, televisions, stereos or the like since their resistant ability against surge is insufficient.

When the inverter drives a motor, the inverters generates pulse current, called “inverter surge”, may damage insulating properties of enameled wire around the motor and interrupt magnetic field of motor, relay, transformer or the like.

Generally speaking, surge applies extremely huge loading to the enameled wire.

If the enameled wire insulating material does not have sufficient insulating strength or cannot evacuate the loading, an insulating layer is easily broken or destroyed, so a coil wound by the enameled wire may cause short-circuit or transmit unstably, and then the electronic devices cannot be used normally or are damaged.

If interface compatibility between them is poor, the metallic oxides agglomerate easily to form particles with large sizes.

However, inorganic material is not soft enough.

If inorganic material is distributed heterogeneously, stress occurs in the enameled wire when the enameled wire is wound into a coil, so electrical and mechanical defaults will damage the enameled wire.

Apparently, how to distribute inorganic material homogeneously is a major problem.

Unfortunately, the quaternary ammonium or phosphonium salts may affect the crosslinking density of the insulating polymer, and then results in the brittle insulating layer peeling off from the conductor.

Images